5 lug brake light question and pedal firmness

[old_blue]

1st -
I finished my 5 lug conversion a few days ago and fired it up today to take it for a spin. Well the battery was dead (pretty new) so I jumped it and immediately noticed my tail lights were on and no one was on the brake. I pulled up on the pedal and the fuse tripped. I replaced the brake light switch and it still either has the brake lights on or the fuse will trip. Do I need to take some material off of the brake booster arm that it hooks up too?

2nd- I notice that my pedal is fairly soft. I think I could floor board it if I wanted to. I put in a 95 brake booster and master cylinder. Maybe I need to bleed it one more time??? any suggestions? does the manual proportioning valve have something to do with this?

thanks in advance guys.

 

[Reed]

I just finished my 5-lug also but I found my pedal felt a bit stiffer. Did you bench bleed the Master Cylinder before connecting the lines to it? It just sounds like it could use another bleeding. For reference my adjustable valve is turned all the way in (full pressure) and I bled the system with it that way.

 

[old_blue]

I bled the system with the knob turned all the way in. I used a pressure bleeder too. Maybe I can do it one more time. Still confused on the brake lights though

 

[old_blue]

ok I found why the tail lights were shorting out. The switch on the pedal was hitting the steering shaft cross member. Has anyone else had this problem? I have no idea why it is hitting that? It won't let the pdeal come back all the way. Anyone have an under dash pic of this?

 

[old_blue]

I also lost that black bushing that goes against the pedal, could this be why the switch hits the cross bar?

 

[Shakerhood]

I also lost that black bushing that goes against the pedal, could this be why the switch hits the cross bar?

I would say that would cause enough give in it to cause the problem. After I installed my 93 Cobra Brake Booster my Brake Lights would stay on, I changed the Switch, also tried an SN95 Style Switch and nothing. As much as I didnt want to try it, I loosened the 4 retaining nuts for the Booster and then wiggled the Booster around to make sure it was seated aginst the firewall all the way. After I tightened the nuts back up it was all good!!!

 

[old_blue]

I will give that a try. does the switch ride on top of that cross member? or just right in front of it. I think I could wiggle the booster around enough to go either way so I will give that a try. If not then I am going to notch that cross bar.

 

[Shakerhood]

Do you have the Correct Booster? If the Arm that comes into the car is Straight then it is WRONG and will hang up on the Crossbar, you need a Booster that has an Arm that Curves Downward like the Factory Booster. If you have the right style Booster and still have interference, you can also go with an Early SN95 Brake switch as it plugs in at 90 degrees instead of straight on like the Fox.

 

[Shakerhood]

Also when you bleed your brakes, make sure the Adj. Prop Valve is turned in all the way to allow full pressure to the rear as its hard to get the air out of the rear lines.

 

[old_blue]

I have a booster from a 95 stang. I tried the 95 style switch but it gets hung up a little as well. Plus it won't go on all the way due to the bracketry being in the way. I didn't get too good of a look at it when I was trying that so I will venture this weekend and try that switch again. I am afraid that I will have to notch that cross member though. Hope it doesn't hurt anything.

The knob is turned all the way in as well. I just need to bleed it again. thanks shakerhood

 

[old_blue]

if you have any other ideas on that switch let me know, I am always up for suggestions.

 

[Shakerhood]

How much did you Elongate your Firewall Holes to fit your 95 Booster in? I always recommend the 93 Cobra Booster as it has the same stud pattern as the Fox, plus the same threads. You may just need to loosen the Nuts and reposition the Booster as the switch should not be hitting like that.

 

[old_blue]

thanks. I am going to work on it this weekend and see if I can push the booster up a little. I think I may have elongated them a little too much. I wanted a 93 booster but I got the 95 for like 10 bucks so I couldn't beat it.

 

[Shakerhood]

thanks. I am going to work on it this weekend and see if I can push the booster up a little. I think I may have elongated them a little too much. I wanted a 93 booster but I got the 95 for like 10 bucks so I couldn't beat it.

I know that cost is always a factor, but sometimes its worth the cash to save you hassles in the future. I highly recommend you try to loosen those nuts and move it around and you might be able to find the optimal spot. Good Luck and let us know how it works out!

 

[old_blue]

will do, thanks again

 

[old_blue]

thanks for everyones help. In the end I just cut the plug off and put on 2 female connectors. A lot easier and no problems with binding at all. I tried to lift up on the booster a little but there is no room for that. I still need to bleed to brakes a few times I guess. oh well.